Remove/install transmission with torque converter

AR27.10-P-0500TW

Remove/install transmission with torque converter

7.2.12

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Before starting work the area around the oil cooler lines must be thoroughly cleaned in the area around the separation points on the automatic transmission. Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the automatic transmission

1

Remove hot film mass air flow sensor

Model 211.080/ 082/ 083/ 280/ 282/ 283

AR07.07-P-1454SV

Model 211.087 /090 /092/ 287 /290 /292

AR07.07-P-1453TS

2

Remove lower engine compartment paneling

AR61.20-P-1105T

3

Drain transmission oil from the transmission oil pan

 If the transmission oil is burnt or interspersed with abrasion, the oil cooler lines and oil cooler must be flushed out.

AR27.55-P-0001A

 Installation: Install new sealing ring.



*BA27.10-P-1001-03A

4

Remove right O2 sensor downstream of CAT (G3/6)

Model 211.080/ 082/ 083/ 280/ 282/ 283

AR14.00-P-5303T

Model 211.087 /090 /092/ 287 /290 /292

AR07.52-P-5303TS

5

Unplug connector of right O2 sensor upstream of CAT (G3/4x1)

Model 211.080/ 082/ 083/ 280/ 282/ 283

AR14.00-P-5303T

Model 211.087 /090 /092/ 287 /290 /292

AR07.52-P-5303TS

6

Detach heat shield and separate plug on the electrohydraulic controller unit

AR27.10-P-0500-01A



*BA27.40-P-1014-01A

7

Detach bracket for O2 sensor connectors (1) at bottom of automatic transmission (5)

 Model 211.080 /082 /083 /280 /282 /283

*BA14.00-P-1003-01A

 Model 211.087/ 090/ 092/ 287/ 290/ 292

*BA14.00-P-1002-01A

8

Detach three way catalytic converter bracket (2)

 Installation: Check tapping plates (4) and replace if necessary.

Model 211.080 /082 /083 /280 /282 /283:



*BA49.10-P-1011-01A



*BA49.10-P-1012-01A

Model 211.087 /090 /092 /287 /290 /292:



*BA49.10-P-1006-01T



*BA49.10-P-1007-01T

9

Detach front axle gear propeller shaft (3) from transfer case flange

 Hold propeller shaft with counterholder. Disconnect propeller shaft at slide connection

AR41.10-P-0070P

10

Detach shift rod from automatic transmission (5)

 To unhook, press the retainer upwards till the shift rod bolt can be removed.

11

Remove bolts (13) for torque converter at driven plate

 Remove cap at front of automatic transmission (5). Turn engine at the crankshaft center bolt in the direction of engine rotation until the bolts (13) of the torque converter are visible.



*BA27.20-P-1002-01C



*001589650900

12

Detach exhaust shielding plate (6) for front propeller shaft (7) behind the transfer case (15)



*BA61.10-P-1005-01C

13

Remove flexible coupling (9)

AR41.10-P-0050-02T

 Installation: Mount propeller shaft on transmission.

14

Loosen fitting sleeve of the flex disk (9) and push back the front propeller shaft (7)

AR41.10-P-0050-09DA

15

Detach ground line from automatic transmission (5)



*BA27.40-P-1013-01A

16

Detach rear crossmember (10)



*BA62.30-P-1001-01A

17

Unhook rear exhaust system from the rubber mounts, lower slightly and secure to prevent it from falling down

18

Support automatic transmission (5) with transmission jack and transmission platform

19

Remove rear engine crossmember (8)

 Rear engine mount remains installed.

AR22.10-P-1160TW

20

Detach retaining clamp of oil cooling lines on engine oil pan

 Pay attention to different lengths of bolts.



*BA27.55-P-1008-01B

21

Remove banjo bolts (11, 12) of oil cooling lines on automatic transmission (5)

  Seal off line connections using plugs.

 Installation: Replace sealing rings.



*BA27.55-P-1002-01B



*129589009100

22

Lower automatic transmission (5) slightly

23

Remove bolts from automatic transmission (5)

 Installation: Pay attention to brackets.



*BA27.40-P-1008-01A

24

Detach oil filler pipe (14) from automatic transmission (5)

 Installation: Replace O-ring at bottom of oil filler pipe (14).



*BA27.10-P-1004-03A

25

Remove automatic transmission (5) at and angle using assembly lift

 Secure torque converter to prevent it from falling out.

26

Remove torque converter

If necessary.

AR27.20-P-0500-01B

27

Install in the reverse order

28

Read out fault memory with STAR DIAGNOSIS and erase if necessary



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

29

Check oil level in automatic transmission (5); correct if necessary

AR27.00-P-0100AC

30

Perform transmission adaptation

A transmission adaptation must be carried out after replacing or repairing the automatic transmission (5).

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

31

Carry out engine test run and check automatic transmission (5) for function and leaks

Number

Designation

Engine
112.917/954

Engine
113.969

Engine
272

Engine
273

BA14.00-P-1002-01A

O2 sensor on catalytic converter

Nm

-

-

50

50

BA14.00-P-1003-01A

Bracket, O2 sensor to transmission

Nm

14

12

-

-

Number

Designation

Trans-mission 722.6 except 722.628/
648/649

BA27.10-P-1001-03A

Oil drain screw to oil pan

Nm

20

BA27.10-P-1004-03A

Bolt, oil filler pipe to transmission housing

Nm

8

Number

Designation

Trans-mission 722.6
except
722.648

BA27.20-P-1002-01C

Bolt, torque converter to drive plate

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

Number

Designation

Transmission
722.6
except 722.660/661/662/663/666/673/674

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

39

M1090

Nm

39

M12

Nm

-

BA27.40-P-1013-01A

Bolt, ground line to transmission housing

Nm

20

BA27.40-P-1014-01A

Bolt, heat shield to transmission housing

Nm

11

Number

Designation

Trans-mission 722.6 in model 211

BA27.55-P-1002-01B

Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

-

BA27.55-P-1008-01B

Bolt, oil cooler line retaining clamp to oil pan

Nm

8

Number

Designation

Engine
112, 113
in model
211

BA49.10-P-1011-01A

Bolt of three way catalytic converter bracket to transmission housing

Nm

20

BA49.10-P-1012-01A

Self-locking nut of catalytic converter bracket to three way catalytic converter

Nm

20

Number

Designation

Engine
272, 273
in model
211

BA49.10-P-1006-01T

Bolt, catalytic converter bracket to transmission

Nm

20

BA49.10-P-1007-01T

Nut connecting catalytic converter bracket to catalytic converter

Nm

20

Number

Designation

Model
211

BA61.10-P-1005-01C

Self-tapping screw connecting front cross strut to frame floor

Nm

23

Number

Designation

Model
211

BA62.30-P-1001-01A

Bolt, crossmember to body

Nm

25